Apparatus and method for winding electrical coils

ABSTRACT

A multiple coil winding apparatus for winding a plurality of layer wound coils of flattened wire on a single insulating winding form common to all of the coils, with insulating sheets common to all of the coils inserted between conductor layers of the coils. A plurality of strands of round conductor are flattened in a wire flattening mill as they are supplied from a wire payoff rack to a multiple coil winding machine. The degree of flattening, or the flattening ratio, of the conductor flattened in the wire flattening mill is readily adjustable, and the flattening pressure applied to the rollers of the wire flattening mill may be readily removed to supply round conductor to the multiple coil winding machine. A roller or rollers of the wire flattening mill may be driven is synchronism with the multiple coil winding machine.

United States Patent Caltagirone [54] APPARATUS AND METHOD FOR WINDING ELECTRICAL COILS [72] Inventor: [73] Assignee: General Electric Company [22] Filed: Feb. 16, 1970 [21] Appl. No.: 11,456

Saverio Caltagirone, Danville, [IL

Lewis ..72/211 5] Mar, 14, 1972 FOREIGN PATENTS OR APPLICATIONS 639,389 6/1950 England ..29/605 Primary Examin'erLowell A. Larson Attorney-John M. Stoudt, Frank L. Neuhauser, Oscar B. Waddell, Joseph B. Forman, Ralph E. Krister, Jr. and Rodford M.Reams [57] ABSTRACT A multiple coil winding apparatus for winding a plurality of layer wound coils of flattened wire on a single insulating winding form common to all of the coils, with insulating sheets common to all of the coils inserted between conductor layers of the coils. A plurality of strands of round conductor are flattened in a wire flattening mill as they are supplied from a wire payoff rack to a multiple coil winding machine The degree of flattening, or the flattening ratio, of the conductor flattened in the wire flattening mill is readily adjustable, and the flattening pressure applied to the rollers of the wire flattening mill may be readily removed to supply round conductor to the multiple coil winding machine. A roller or rollers of the wire flattening mill may be driven is synchronism with the multiple coil winding machine.

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Attorney APPARATUS AND METHOD FOR WINDING ELECTRICAL COILS CROSS REFERENCES TO RELATED APPLICATIONS assignee as the present application, and filed on the same day as this application is expressly incorporated by reference in the present application:

Improved Apparatus and Method For Winding Electrical Coils Saverio Caltagirone, Ser. No. 11,455, filed on the same day as this application.

BACKGROUND OF THE INVENTION 1 FIELD OF THE INVENTION This invention relates to a method and apparatus for the multiple winding of layer wound coils of flattened conductor wire on a single insulating winding form common to all of the coils, with insulating sheets common to all of the coils inserted between the layers of the coils.

2. DESCRIPTION OF THE PRIOR ART As is set forth in two of the abovementioned crossreferenced applications, both of which are entitled; Apparatus For Starting And Operating Electric Discharge Lamps, considerable advantage can be realized with respect to the space factor of layer wound coils, sheets between winding layers, by winding the coils with flattened conductor wire. While the advantages of forming coils of flattened conductor wire set forth in great detail in the just mentioned applications, and more particularly in the application Ser. No. 604,417, generally the use of flattened wire provides by more eflicient use of the window space, wherein a greater percentage of the space between layer insulation sheets is filled with conductor material. Further, with the conductor wire flattened on at least two sides, and with a flattened side wound on the layer insulation, the larger surface area resting on the layer insulation distributes the force applied to the layer insulation by the conductor winding tension during winding over a greater surface area, so that thinner layer insulation may be utilized. Taking into account the various factors effecting the optimum use of a coil crosssectional area, ti has been found that for various electrical requirements imposed upon a coil to be wound with the same coil cross-sectional area, that various degrees of flattening or flattening ratios, are required to provide the maximum space factor for optimum use of the coil cross-sectional area.

While flattened wire has been available in the past, and is now available from wire mills, due to the needs of standardization in such wire mills, and infinite selection of flattening ratios is not readily available at economic costs. Further, more difficulty is experienced in feeding flattened conductor wire to multiple coil winding machines than is the case with round wire, since flattened wire has a greater tendency to be twisted, so as to possibly be kinked. It has also been found that it is harder to insulate flattened wire which has already been flattened. Other problems are also presented by the use of flattened wire obtained from a wire mill for use in a multiple coil winding machine. For instance, the reeling and dereeling of flattened wire tends to work harden the wire to. a greater extent than is the case with round wire. Further, keeping the flattened wire on a spool is more troublesome than is the case with round conductor wire.

Thus, it would be desirable to provide a method and apparatus for multiple winding of layer wound coils with flattened conductor, wherein the degree of flattening or flattening ratio is readily adjustable, and wherein the conductor can be provided a round conductor wire just prior to the winding of the electrical coils, so as to avoid the numerous problems encountered in handling flattened conductor wire. It would be further desirable if such a method and apparatus for winding multiple coils of flattened wire would permit the coils to be wound with certain turns not flattened, such that those turns might from round leads for the coil.

SUMMARY OF THE INVENTION Accordingly, it is an object of this invention to provide a method and apparatus for multiple winding of layer insulated coils with flattened conductor wire, wherein the wire is flat tened just prior to being wound in the coils.

It is a further object of this invention. to provide a method and apparatus for winding multiple coils of flattened conductor wire wherein a wire flattening mill simultaneously flattens the plurality of conductor wires as they are being fed to the multiple coil winding machine.

Still another object of this invention is to provide a method and apparatus for winding multiple coils of flattened conductor wire wherein a wire flattening roller mill is provided in conjunction with a multiple coil winding machine to flatten all of the conductors with precisely the same spacing between the flattened sides, and wherein a roller or rollers of the wire flattening roller mill are driven in synchronism with the multiple coil winding machine so as to provide a predetermined tension in the flattened conductor wire supplied to the multiple coil winding machine.

It is still another object of this invention to provide a method and apparatus for multiple winding of coils with flattened conductor wire wherein the conductor wires are provided as round conductors and are flattened just prior to the winding of the coils, and wherein turns of round conductor can be wound in the coil so as to provide around conductor leads for the coil.

In carrying out the objects of the invention, there is provided with'a standard commercially available multiple coil winding machine a wire flattening rolling mill in which the multiple strands of round conductor wire are flattened as they are fed to the multiple coil winding machine. In one form of the invention the force required to draw the conductor wires through the rollers of the wire flattening mill to be flattened is provided by the multiple coil winding machine. In another embodiment of this invention one of the rollers of the wire flattening roller mill is driven, such that essentially all of the force required to draw the multiple strands of wire between the rollers of the wire flattening mill to be flattened is provided by the driven roller. However, a small amount of force must still be provided by the multiple coil winding machine, such that the wire flattening mill serves as a precise wire tensioning device for the coil winding machine.

In still another embodiment of this invention both of the rollers of the wire flattening mill may be driven so as to provide the capacity to flatten larger conductors than may be flattened where only one of the rollers is driven.

The subject matter which I regard as my invention particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention itself, however, together with further objects and advantages thereof, may be best understood by making reference to the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an apparatus for winding multiple coils of flattened wire in accordance with this invention;

FIG. 2 is front view of the wire flattening mill shown in FIG.

FIG. 3 is a partial sectional view of the wire flattening mill shown in FIG. 1;

FIG. 4 is a cross-sectional view of the wire flattening mill taken along the line 4-4 in FIG. 3;

FIG. 5 is a top plan view of the wire flattening mill assembly shown in FIG. 1;

FIG. 6 is a front plan view of another embodiment of wire flattening mill which may be used in accordance with another embodiment of this invention;

FIG. 7 is a front plan view of still another embodiment of a wire flattening mill, including a drive means, which may be used in accordance with still another embodiment of this invention;

FIG 8 is a schematic diagram for purposes of illustrating certain principals of the method and apparatus of this invention;

FIG. 9 is a circuit showing a control circuit in accordance with the method and apparatus of this invention;

FIG. 10 is a circuit diagram showing a control circuit in accordance with the method and apparatus of this invention;

FIG. 11 is still another circuit diagram showing a control circuit in accordance with the method and apparatus of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1 the apparatus in accordance with this invention for winding multiple coils of flattened wire will be understood. Generally, an apparatus in accordance with this invention comprises three portions, a wire payoff rack 10, a wire flattening mill assembly 12, and a multiple coil winding machine assembly 14. Multiple strands of wire or conductor are provided from the wire payoff rack 10 to the wire flattening mill assembly 12 wherein it is flattened, and it is thereafter fed to the multiple coil winding machine 14 wherein it is wound in the customary manner to form multiple coils of flattened wire.

The wire payoff rack 10 supports a number of spools of wire 16 equal to the number of coils which are to be wound on the winding machine. The wires pass over suitable guiding means such as pulleys l8 and 20 to be guided to the wire flattening mill assembly 12. While it has been found that proper wire tension for winding may be maintained in accordance with certain embodiments of this invention by the synchronization of the-wire flattening mill with the winding machine, it may in other cases be desirable to replace one of the guide pulleys 18 or 20 with a tensioning device. For instance, an electromagnetic wire tension device as described in US. pat. No. 2,845,235-Wilcox issued July 29, 1958, and assigned to the assignee of this application may be utilized.

From the wire payoff rack 10 the wire is fed to a wire flattening mill 22 wherein it is guided between a pair of spaced wire flattening rollers 24 and 26 by passing through guide bushings in guide plates mounted at each side of the wire flattening rollers. Only guide bushing plate 28 for guiding the wire out of the wire flattening mill is shown in FIG. 1. The wire which has been flattened in the wire flattening mill 22, in a manner which will hereinafter be described in further detail, is then fed to a wire guide receiving rack 30 of the multiple coil winding machine assembly 14. In the wire guide receiving rack 30 the wire is received over a series of guide rollers 32, passed under a series of guide rollers 34 which are pivotally mounted from a shaft 36, and thereafter passed over a third set of guide rollers 38 to be fed to the two sets of guide rollers 40 and 42 in the wire payoff carriage assembly 44 of the multiple coil winding machine assembly 14.

The multiple coil winding machine is a standard coil winding machine wherein multiple coils are wound on an insulting tube, with layers of paper being automatically inserted between layers of conductor. Such coil winders are for instance available from the Leesona Corporation Warwick, Rhode Island. One such coil winder is identified as the Leesona Model No. 107.

The multiple coil winding machine assembly 14 is shown as comprising a self contained structure with a platform 46 supported by upstanding legs 48 and 49, which in a typical winding machine may include operating mechanisms of the coil winding machine. In the coil winding machine shown, the leg 48 is shown as a housing which would enclose the drive mechanism for the coil winding machine. The drive mechanism synchronizes the several operations necessary to wind multiple coils. For instance, it causes rotation of a shaft 50 which causes rotation of the elongated insulating tube or spool form upon which the multiple coils are wound. The rectangular insulating tube 52 is supported at the right end by a bracket 54 and at the left end by the shaft 50 extending from the upstanding leg or housing 48. Rotation of the shaft 50 will cause the tube 52 to rotate, whereby wire may be wound around it. Further, in accordance with the usual construction of multiple coil winding machines, the drive mechanism included in the winding machine housing 48 causes traversal of the payoff carriage assembly 44 with respect to the insulating tube 52 to wind turns of wire in a side by side relationship in a single layer on the insulating tube 52. More particularly, the cylindrical bars 56 and 58 upon which the payoff carriage assembly 44 is supported, are driven by mechanisms within the housing 48 to provide the desired transversing motion of the wire payoff carriage assembly 44.

Generally, assuming that a layer of coil winding is started at the left, the wire payoff carriage assembly 44 will move to the right through motion imparted by movement of the supporting cylindrical bars 56 and 58, until the desired number of turns is wound in the layer: At that point, in accordance with the usual construction of such multiple coil winding machines, a layer insulation such as a sheet of paper will be inserted over the layer of coil turns, and the wire payoff carriage assembly 44 will then again moving to the left, to wind a second layer of coil turns over the layer insulation and the preceding layer of coil turns. Such traversing of the wire payoff carriage 44 and insertion of layer insulation continued until the desired number of turns in the coil are provided.

While adequate dwell time at the reversal of the wire payoff carriage traverse is necessary for insertion of the layer insulation is paper to the strip of coils, at the same time it is most desirable that the wire payoff carriage has moved an adequate distance after the reversal to assure that the first turn of the succeeding coil winding layer is wound over the layer insulation directly over the hard bed of the turns of the previous layer, such that the turn will not fall in the critical marginal area of the coil where it would have a tendency to fall down on the margins or cause a multitum buildup.

It is even more critical in winding wire which has been flattened on a pair of opposite sides than in the case of round wire that the first turn of the succeeding coil winding layer be wound on the hard bed of the turns of the previous layer. For instance with flattened wire it is possible to utilize thinner layer insulation, wherein the flattened surface spreads the force of winding tension over a greater area of the paper. However, at the same time if the first turn of the succeeding coil winding should fall down on the margin, its relatively thin edge would very easily cut the underlying layer insulation.

To overcome this critical condition in winding coils of flattened wire in standard multiple coil winding machines, the winding machine assembly 14 shown in FIG. 1 is provided with an improved apparatus 60 for reversing the direction of travel of the wire payoff carriage. This improved apparatus 60 is the subject matter of my copending application entitled, Improved Method and Apparatus for Winding Electrical Coils, Ser. No. 1 1,455, filed on the same day as this application and expressly incorporated by reference in this application as hereinbefore set forth.

Looking in greater detail at the wire flattening mill assembly 12, the wire flattening mill 22 and its drive means 61 are mounted on raised platform 62. While the wire flattening mill assembly 12 is shown being separately supported, it is of course only necessary that a satisfactory relationship be established between the entrance and exit guide bushing plates of the wire flattening mill 22 and the exit guide pulleys 20 of wire payoff rack and the entrance guide rollers 32 of the winding machine assembly respectively. This being the case, other physical arrangements of the wire payoff rack 10, the

wire flattening mill assembly 12, and the coil winding machine assembly 14 are of course possible and entirely feasible. For instance, members 64 and 66 which are shown supporting the wire guide receiving rack 30 of the multiple coil winding machine assembly 14 could also provide support for the wire flattening mill assembly by providing suitable brackets thereon.

Referring now to Figs. 2, 3, and 4, the embodiment of the wire flattening mill shown in FIG. I, will be described in further detail. The wire flattening rollers 24 and 26 are supported within a housing 68, which as is shown in FIG. 3 may be formed of upper side wall portions 70 fitted and secured to a base portion 72. Secured to the upper sidewall portions 70 is a top 74. The flattening rollers 24 and 26 are provided with shafts extending from each end thereof which are supported by four similar bearing arrangements. Each of the rollers 24 and 26 is formed with a shaft of variable diameter, upon the central portion of which is secured an extremely hard ring to form the actual flattening surface of the rollers. For instance, the upper roller 24 is formed of a shaft 76 around the middle portion of which is shrunk fit a carbide ring 78 having an extremely true and accurate cylindrical surface. For instance, carbide ring 78 may be a three quarters inch thick General Electric grade 558 carbide tire. Similarly, the lower flattening roller 26 is formed of a shaft 80 and a carbide ring 62.

In a preferred embodiment of my invention the ends of the upper shaft '76 and the lower shaft 60 are joumaled in four identical bearings arrangements 64, 86, 66 and 90, each of which includes a pair of contained rings or cone bearings. Each of these hearings is enclosed within a housing, which as is shown in FIG. 3 are provided with seals, such that lubricant may be contained within the housings under pressure to lubricate the bearings. The bearing housings are formed with considerable strength, such that the pressure may be applied to the roller through the housings. The shaft 60 of the lower roller 26 extends through the left wall of the housing 66, and is provided with a keyway 92 whereby it may be keyed to a timing chain sprocket 94.

The spacing between the flattening rollers 24 and 26, and therefore the thickness of wire flattened between the rollers, is determined by spacers 96 and 96 which are inserted between the upper and lower bearing housings. Thus, to change the thickness of wire flattened between the rollers 24 and 26, it is only necessary to use spacers 96 and 96 of different thicknesses.

In order to insert and remove the spacers 96 and 96 from between the upper and lower bearing housings a means is provided for lifting the upper roller 24 and its bearing housings. At best shown in FIGS. 3 and 4, this lifting means includes a metal plate or bar 160 which is provided with apertures H02 and 104 for receiving bolts 106 and 106 which are threadedly secured in the top portions of the upper bearing housings. A shaft Illtl journaled in the front and rear walls of the wire flattening mill housing 68 is provided with an eccentric portion 112 which engages the bar 100, such that when the shaft H0 is rotated by the handle 114, the engagement of the eccentric portion 112 of the shaft with the bar 100 will cause the upper bearing housings and roller 24 to be lifted. Thus, by manually rotating the shaft 11110 the upper roller 24 and its supporting bearing housings may be lifted to change the spacers 96 and 96.

As thus far described, the only downward force upon the upper flattening roller 24 which would be applied to conductors passing between the upper and lower rollers 24 and 26 respectively would be that attributable to the weight of the upper roller 24 and its bearing housings. During operation of the wire flattening mill, the upper roller 24 is maintained at its predetermined spacing from the lower roller 26, as determined by the spacers 96 and 98, by pressure applied to the upper roller bearing housing by a hydraulic cylinder 11l6. Sufficient pressure is applied to the upper bearing housings to continuously maintain them in engagement with the spacers 96 and 96, such that they are not lifted by reason of the conductors which are passing between and being flattened by the rollers 24 and 26. The hydraulic cylinder 1 16 is secured to the top of the rolling mill housing 68 by four bolts, three of which 1116, I20, and I22 are shown in FIGS. 3 and 4. The piston of the hydraulic cylinder 116 which is not shown, is connected to the shift 124, which engages a rigid metal plate 126. Pressure which is applied to the rigid plate 126 by the hydraulic cylinder 1116 is in turn applied to the top of the upper roller bearing housings through four pins, three of which I26, 136, and 1132 are shown in FIGS. 3 and 4. The four pins, including pins 112%, 1130 and 1132, pass through bores in a metal plate I34 which is secured to the walls of the wire flattening mill housing.

In order to insure that the plural strands of wire to be flattened between the rollers 24 and 26 pass therebetween in a side by side relationship, such as not to overlay each other, and such that they are spaced sufficiently apart so that they do not engage the sides of each other when flattened, guide bushing plates are provided for accurately determining the entrance and exit positions of the conductors being flattened between the rollers. As is best seen in FIG. 4, generally identical guide bushing plates 28 and I36 are provided for aligning the conductors for passage between the flattening rollers. Referring to FIGS. 2 and 4, it will be seen that the guide bushing plate 28 is supported on a pair of metal rods 1138 and 1140, which in turn are supported by a bracket 1142 which is secured by a fastening means 144 to the sidewall of the flattening mill housing. The guide bushing plate 28 is supported on the metal rods 1138 and 1140 by a split bushing plate support 144 which clamps around the metal rods I38 and and is releasably secured thereto by a threaded fastener 146. Thus, the guide bushing plate 28 may move away from the wire flattening rollers when the conductors are to be inserted through the apertures in the guide bushing plate and between the wire flattening rollers. After the conductors have been threaded through the aperture and between the wire flattening rollers, the guide bushing plates may be moved as close to the rollers 24 and 26 as is necessary to accurately position the conductors between the rollers.

Wherein there is considerable friction between the c0nductors and the apertures in the guide plates, the apertures are provided with solid Carboloy guide bushings. It should be pointed out, that the flattening mill as shown in FIGS. 1, 2, 3, and 4 is used with small wire sizes, such as 0.040 inches diameter, and that in order to show the apertures in the guide plates, they are considerably exaggerated in size. Thus, while it might appear in looking at the guide bushing plate 28 as shown in FIG. 2 that the conductors would overlap each other, they are in actual fact as hereinbefore stated, sufficiently spaced apart such that even after flattening they do not overlap or even touch each other as they pass between the rollers of the wire flattening mill.

Having now described the wire flattening mill 22, the means for driving the lower roller 26 will be explained by making reference to FIGS. 1 and 5. The lower roller 26 is driven by a drive means 61 which as is most clearly shown in FIG. 5 includes a motor 148, and a magnetic clutch I50. The motor 146 drives the magnetic clutch 150 through a timing belt 152 which engagestiming belt pulleys (not shown) keyed to the shafts 154 of the motor and 156 of the magnetic clutch. The timing belt 1152 is suitably enclosed within an enclosure 1158. The output of the magnetic clutch 150 is coupled to the wire flattening mill 22 by a timing chain 160. The output shaft 162 of the magnetic clutch is provided with a suitable timing chain sprocket (not shown), for engagement with the chain 160, and the timing chain sprocket 94 keyed to the shaft 80 of the lower roller 26 of the wire flattening mill also engages the chain 160.

In a preferred embodiment of this invention the drive motor 46 is a DC motor, the speed of which is adjustable. For instance, in one embodiment of this invention a General Electric three horsepower, volt, l5 ampere, 0.07 field ampere, DC motor is controlled through a General Electric GP 100 Adjustable Speed Drive Unit. The magnetic clutch 150, which is adjustable to determine the amount of torque transmitted from the motor 148 to the lower roller 26 of the wire flattening mill 22 is a Vickers Magneclutch, Model Number 6-2 3, rated as follows, maximum rpm. 18,000, volts DC 90, amperes 0.51, Torque 45 pound feet. The mode of operation os such a magnetic clutch as set forth in patent No. 2,684,138 issued July 20, 1954. This magnetic clutch 150 is water cooled, as indicated by the water inlet and outlet connections 164 and 166.

The wire flattening mill assembly 12 as shown in FIGS. ll through 5, has the lower roller 26 of the wire flattening mill 22 driven, so as to draw the wire to be flattened between the flattening rollers 24 and 26. Depending upon the flattening ratio desired, the conductor material, and the wire size among other factors, it may be found desirable to have both flattening rollers 24 and 26 driven, or in other cases it may be found that neither of the flattening rollers need be driven.

For example, if it is found that only a limited amount of wire flattening is desired, and that the wire is of sufficient size to have the required tensile strength to be pulled through the flattening rollers, then in such cases, it is not necessary to drive either of the flattening rollers. In such an arrangement the winding machine provides the force necessary to pull the wires through the wire flattening mill. Such a nondriven wire flattening mill is shown in FIG. 6. Generally, the winding mill shown in FIG. 6 is essentially the same as the wire mill having the lower flattening roller driven as shown in FIGS. 1 through 4. Basically, all that need to be changed is to provide a lower roller 26 which is identical to the upper roller 24 as shown in the wire flattening mill depicted in FIGS. 1 through 4. Apart from this, only the lower portion of the housing need to be modified to eliminate the bore provided for the shaft 80 as shown in FIG. 3.

However, since the flattening ratios which are feasible with an undriven mill are considerably less than those in a wire flattening mill having one of the rollers driven, the pressure which need be exerted on the. upper flattening roller to hold it in position against the spacing blocks, so as to maintain the predetermined spacing between the rollers to give the precise flattening desired is less. Thus, the size of the structure could be readily reduced, using perhaps smaller diameter rollers, and also small bearings and a smaller hydraulic cylinder.

When larger size wires are to be flattened, and when a greater flattening ratio is desired, it has been found that in a wire flattening mill with only the lower roller driven, as shown in FIGS. 1 through 4, that the wire will not be properly fed between the rollers. Rather, it will skid with respect to the undriven roller, such as the top flattening roller 26 as shown in FIGS. 3 and 4. This skidding can be limited, so as to flatten heavier wires with a greater flattening ratio, by driving both of the rollers as is depicted in the wire flattening mill shown in FIG. 7.

The wire flattening mill shown in FIG. 7 is essentially the same as that shown in FIGS. 1 through 5, differing only in that means are provided for driving both the upper and lower wire flattening rollers. The only modification necessary to the wire flattening mill shown in FIG. 1 through 4 to provide the upper roller 24 with the same longer shaft as is provided on the lower roller in the wire flattening mill shown in FIG. 3. Of course, an aperture must be provided in the upper sidewall for the shaft, and a bearing support must be secured to the outside thereof.

Considering further the wire flattening mill shown in FIG, 7, those components which could be identical to those of the wire flattening mill shown in FIGS. 1 through 5 are identified with the same identifying numeral. The drive shaft 80 of the lower roller 26, and a drive shaft 168 of the upper roller 24 are both driven through a gear box 170. The same drive means as shown in FIG. 5, may be used to drive timing chain gear 172, which is keyed to a shaft 174 which extends through and is journaled in the gear box 170. Within the gear box a gear 176 is keyed to the shaft 174, and at the right end the shaft 174 is keyed one side of a flexible shaft coupling 178. Within the gear box 170 is a second gear 180 which is keyed to a shaft 182 which is joumaled in the gear box 170 and extends through the right side thereof and is keyed to one side of a rigid drive shaft coupling 184. The end of shaft of the lower wire flattening roller 26 is also keyed to the rigid shaft coupling 184, while the end of shaft 168 of the upper wire flattening roller 24 is secured to the flexible shaft coupling 178. Thus, the upper wire flattening roller 24 and the lower wire flattening roller 26 are driven at the same speed through the gear box 170. Wherein the gear box 170 and the wire flattening mill housing 68 are mounted on the same platform, the rigid shaft coupling 184 may be used to couple the lower flattening roller 26 to the lower shaft 182 of the gear housing. However, wherein the upper wire flattening roller 24 is raised and lowered by the hydraulic cylinder 116, its shaft 168 extending from the left side of the wire flattening mill housing 68 will also be raised and lowered by a slight amount, such that the flexible shaft coupling 178 is needed.

Considering now the modes of operations of an apparatus for a multiple winding of flattened wire conductors utilizing an apparatus as shown in FIG. 1, but with the three different types of wire flattening mills, i.e., none of the wire flattening rollers driven, one of the wire flattening rollers driven, and both of the wire flattening rollers driven. A flattened wire multiple coil winding apparatus as shown in FIG. 1, wherein neither of the following rollers are driven, will rely on the multiple coil winding machine assembly 14 to provide the necessary tension on the strands of wire to draw them between the wire flattening rollers. Thus, considerable tension will be applied to the conductors as they are fed to the multiple coil winding machine, and on other special tensioning means would ordinarily be required. However, a tensioning means should be provided, such as on the wire rack assembly 10, to provide tension in the conductors being fed to the multiple coil winding machine 14 when pressure on the rollers is released so as to feed round unflattened conductor to the winding machine.

As is set forth in my related application: Apparatus for Starting and Operating Electric Discharge Lamps, assigned to the same assignee as this application and filed on the same date as this application, it has been found desirable in the multiple winding of electric coils to provide the ability to wind certain numbers of turns at certain times with round wire, while generally in winding the layers of the coil to be winding flattened wire. Thus, in the flattened wire winding machine assembly as shown in FIG. 1, it is desirable to be able to wind certain turns of the multiple coils without flattening the same. In those cases where the winding machine is operated manually when beginning to wind a coil and at the end of winding the coil, being automatically operated only throughout the rest of the winding, it is of course possible to provide a manual means for applying and removing the hydraulic pressure applied to the hydraulic cylinder on the wire flattening mill.

However, if the entire winding of the coils is automatically controlled by the winding machine, the winding machine would necessarily include turns counters, the electrical outputs of which would control the winding machine in a customary manner. Such being the case, the application of the hydraulic pressure to the hydraulic cylinder on the wire flattening mill could be controlled by a solenoid valve, the energization of which is in turn controlled by the electric outputs of the turn counters. Thus, in order to provide coils wherein the first turn or turns of the first layer of winding and the last turn or turns of the last layer of winding are formed of round conductor, the turn counters would provide signals not only to start and stop the arbor drive of the winding machine, but also to actuate a solenoid valve controlling the application of hydraulic pressure to the hydraulic cylinder applying pressure to the upper roller of the winding mill.

When only one roller, such as the lower roller 26 of the wire flattening mill shown in FIGS. 1-5 is driven, or when both rollers are driven as shown in FIG. 7, the performance of the flattened wire winding apparatus is improved provided by synchronization of the speed of the driven roller or rollers of the wire flattening mill with the winding speed of the multiple coil winding machine. Generally, this synchronization of the drive of the wire mill with the coil winding machine would be the same whether one roller or both rollers are driven.

in order to better understand the desired synchronization of the automatic coil winding machine with the wire flattening mill, reference is made to FlG. 8. in this FlG. the upper flattening roller 2d and the lower flattening roller 26 are shown flattening a round conductor C. As shown by the arrows 1F a force is applied to the upper flattening roller 24 to maintain the upper roller in contact with the spacer bar separating the bearings housings of the upper and lower rollers, so as to maintain uniform flattening of the conductor. A portion of the mechanical force F is applied to the upper flattening roller M to flatten the conductor C. The upper flattening roller 24 runs free being caused to rotate by friction with the conductor C. The bottom roller 26 is driven by the motor ll tlll through the magneclutch, a device through which the amount of torque delivered from a driving means such as the motor M3 to a load such as the roller 26 can be readily controller. Thus, in accordance with a preferred mode of operation of the flattened wire coil winding apparatus of this invention, the magneclutch 159 is adjusted to deliver a tangential force to the roller 26 along the axis of the conductor C. it has been found it is preferable that this force X be somewhat less than that necessary to cause the conductor to pass between the upper and lower rollers 24 and 26. This being the case, the coil winding machine will then provide the slight additional force necessary to draw the conductor C between the flattening rollers 24 and 26 to feed flattened conductor wire to the automatic multiple coil winding machine. Thus, in a preferred mode of operation of a flattened wire multiple coil winding apparatus of this invention, the force applied to the conductor C to move it between the rollers to be flattened is primarily supplied through the magneclutch 150 to the lower roller 26, but with a slight additional force being required from the winding machine. By accurate adjustment of the torque provided to the lower roller 26 by the magneclutch 150, the wire rolling mill will serve as an accurate tensioning device for the conductors supplied to the automatic coil winding machine.

As set forth hereinbefore with respect to the nondriven wire flattening mill, it is desirable to wind flattened wire multiple coils with certain turns not flattened. Therefore, it is also desirable to provide control of a power driven wire flattening mill such that such non-flattened turns may be wound. Thus, as in the case of the nondriven wire flattening mill, it is desirable to synchronize the application of hydraulic pressure to the hydraulic cylinder in a power driven wire flattening mill with the operation of the automatic multiple coil winding machine. As set forth with respect to the nondriven wire flattening machine, this may be done by providing additional counters, or additional contacts on the regular counters on the multiple coil winding machine, so as to control a solenoid valve which controls the application of hydraulic pressure to the hydraulic cylinder on the wire flattening mill.

In an apparatus for winding multiple coils of flattened wire, wherein the wire flattening rollers are power driven, a force is applied to the conductors being flattened through the magnetic clutch H56 to aid in moving them between the rollers of the wire flattening mill to the winding machine. Since this force varies with the wire speed, which is determined by the winding speed of the automatic coil winding machine, it is necessary to synchronize the torque supplied to the winding mill roller 24 by the magnetic clutch 156, with the operation of the automatic winding machine. In the normal operation of a multiple coil winding machine, the winding is generally done at a high speed, while at the start and finish of a coil winding, or at a portion wherein it is desired to provide a tap, the winding speed is considerably reduced. Wherein the driving force applied to the conductors being flattened by the wire flattening mill from the magnetic clutch is very close to that required to feed the wire to the winding machine, should the magnetic iltl clutch continue to supply the torque necessary to feed the conductor at the high winding speed after the winding machine has slowed down, an excess of flattened wire would be quickly fed to the winding machine, and would of course render the winding machine inoperative.

Thus, in the preferred embodiment of this invention it is desirable that means be provided to adjust the torque transmitted by the magnetic clutch in accordance with the winding speed of the automatic coil winding machine. The winding speed in the normal automatic coil winding machine is controlled electrically through circuits controlled by contacts on turn counters. Thus, by providing additional contact on the turn counters, or additional turn counters, these contacts may be used to control the amount of power supplied to the magneclutch, thereby controlling the amount of torque delivered from the motor 154 through the magnetic clutch 1156 to the wire flattening mill.

Wherein the amount of torque delivered to the roller or rollers of the wire flattening mill is controlled by the magnetic clutch 1156, it is unnecessary to provide automatic variable speed control of the motor R54. The only requirement placed on the operation of the motor 154 is that when it is energized to deliver torque to the magnetic clutch 1156, that it run at a speed sufficient to insure that the roller or rollers in the wire flattening mill be driven with the required torque at the greatest speed necessary to supply flattened wire to the winding machine at its greatest winding speed.

The fine details of the electrical control circuiting used to synchronize the power driven wire flattening mill with the automatic multiple coil winding machine, will not be set forth herein, since such circuitry would of course be entirely dependent upon the particular automatic coil winding machine utilized with a wire flattening mill in accordance with this inven tion. However, the basic principals of such control circuits will be set forth by making reference to F I65. 9, 10 and 1111. Referring to FIG. 9, connected between a pair of bus bars 184 and 1186, energized from an alternating current power source, are a series of parallel paths including the contacts CC-ll through CC-fi of a plurality of turns counters driven with the winding arbor of the automatic coil winding machine, and the actuating coil CR-l through CR-S of a plurality of contactors used to control the energization of the magnetic clutch 1150 and the application of hydraulic pressure to the wire flattening mill rollers. As indicated to the right of H6. 9, the actuation of the counters CC-1l through CC-d may indicate a run, jog, break, or stop condition of the automatic winding machine, and therefore a desire to condition energization of the magnetic clutch 1156.

Referring to H6. lltl, a power supply ran provides an ad justable DC output at terminals 190 and 192 from an alternating current supply at terminal 194 and 1196. The DC output appearing at terminals 190 and 1192, which is applied to the magnetic clutch 1150, is controlled by the amount of resistance appearing between the control terminals 198 and 29th of the power supply. Connected in parallel between the control terminals 1198 and 200 of the power supply are the contacts Cl-1l, C2-11, C3-1l, and C5-1l of the contactors actuated by the coils ClR-l through CR-S respectively, connected in series with variable resistances R R R and R Thus, each of the resistance values R R R and R may be adjusted to provide the desired DC output at terminals 196 and 1192 for supply to the magnetic clutch when the multiple coil winding machine and the wire flattening mill are the run, jog, break, and stop conditions. As shown in FIG. lit), the DC output at terminals 199 and 192 increases as a greater amount of resistance appears between control terminals 119% and 290. Therefore, wherein the greatest torque is desired to be transmitted by the magnetic clutch 150 when the winding machine is in a run condition, the resistance R, is the greatest, and wherein the jog, break and stop conditions of the winding machine are at successively slower speeds, the resistance values 1R R and R are of successively lower values. Finally, when the turns counter contact CC-5 closes, to energize the relay coil CR-S to indicate that the pressure on the rolling mill is to be released to provide round conductor, the contact CS-l is closed directly across the tenninals 198 and 200, to

- reduce the power supply from output terminals 190, 192 to the magnetic clutch 150 to 0. Thus, when the pressure on the wire flattening mill rollers is removed, the necessary torque for winding the coils is supplied only by the automatic coil winding machine.

As shown in FIG. 11, the contactor actuating coil CR-S has a second contact C-2, which controls the energization of a solenoid valve 200 which is energized from an AC power supply 202 and 204. This solenoid valve 200 controls the application of hydraulic pressure to the hydraulic cylinder 116 on the wire flattening mill. Thus, when the contact C5-2 is closed by energization of the contactor actuating coil CR-S the solenoid valve 200 is energized to remove the supply of hydraulic pressure to the wire flattening mill hydraulic pressure to the wire flattening mill hydraulic cylinder 116. As further shown in FIG. 9, it may of course be desirable to provide manual control of the various conditions of energization of the magnetic clutch 150. Thus, for instance, a manual switch 206 may be provided for controlling the energization of contactor actuating coil CR-S, to relieve the hydraulic pressure on the wire flattening mill hydraulic cylinder 116, and to remove the power input to the magnetic clutch 150.

It should be apparent to those skilled in the art that while I have described what, at present, is considered to be the preferred embodiments of this invention in accordance with the Patent Statutes, changes may be made in the disclosed apparatus and method without actually departing from the true spirit and scope of this invention.

What I claim is new and desire to secure by Letters Patent of the United States is:

1. Apparatus for winding at least one coil of flattened electrical conductor wire from round conductor wire, comprising:

a. an electrical coil winding machine including an arbor on which the at least one coil is wound, said arbor being driven to wind the conductor wire thereon;

b. a supply of round conductor wire,

c. a wire flattening mill interposed between said supply of round conductor wire and said coil winding machine for flattening the conductor wire as it passes from said supply to said winding machine;

d. said flattening mill including a pair of spaced apart flattening roller means for selectively flattening the conductor wire as it passes therebetween; means for selectively applying a force to maintain said roller means spaced apart a predetermined amount to flatten the conductor wire and for removing the force so that non-flattened conductor wire will be provided to said arbor.

2. Apparatus as set forth in claim 1 in which one of said roller means is movable relative to the other of said roller means; spacing means is operatively positioned between said roller means for providing the predetermined space between said roller means; said means for applying force being selectively effective to maintain said movable roller means in operative engagement with said spacing means.

3. Apparatus as set forth in claim 2 wherein said spacing means may be varied, while the force is removed, to alter the predetermined amount of space between said roller means.

4. Apparatus for winding a plurality of coils of flattened electrical conductor wire from round conductor wire, comprising;

a. an electrical coil winding machine including an arbor about which the plurality of coils are simultaneously wound;

a wire supply for providing a plurality of strands of round conductor wire and c. a pair of spaced apart flattening rollers positioned between said arbor and said wire supply, the plurality of strands of conductor wire passing between said rollers for simultaneously flattening all the strands of conductor wires to substantially the same degree immediately before they are wound about said arbor. 5. Apparatus as set forth in claim 4 further including drive means for applying a torque to at least one of said flattening rollers, the amount of applied torque being insufficient to feed the strands of conductor wire; said winding machine simultaneously applying a force to the strands of conductor wire so that the strands of conductor wire will pass between said flat tening rollers and be wound about said arbor.

6. Apparatus as set forth in claim 4 in which one of said rollers is movable relative to the other of said rollers; spacing means is operatively positioned between said rollers to provide a predetermined space between said rollers; and means selectively applying a force to said movable roller for maintaining said movable roller in operative engagement with said spacing means; so that flattened strands of conductor wire are provided to said arbor when the force is applied and non-flattened strands of conductor wire are provided to said arbor at other times.

7. Apparatus as set forth in claim 6 in which said spacing means is selectively variable to alter the predetermined space between said flattening rollers.

8. Apparatus as set forth in claim 5 further including synchronizing means for adjusting the torque output of said drive means in accordance with the operation of said coil winding machine, such that said drive means will always supply insufficient torque to feed flattened conductor wire to said winding machine without said winding machine applying a force to the conductor wire.

9. Apparatus for winding at least one coil of flattened electrical conductor wire from round conductor wire, comprising:

a. an electrical coil winding machine including an arbor on which the at least one coil is wound, said arbor being driven to wind the conductor wire thereon;

a supply of round conductor wire;

0. a wire flattening mill interposed between said supply of round conductor wire and said coil winding machine, including a pair of spaced apart flattening rollers for flattening the conductor wire as it passes therebetween;

drive means for applying a torque to at least one of said flattening rollers tending to feed the conductor wire between said rollers and;

e. synchronizing means for adjusting the torque output of said drive means in accordance with the operation of said coil winding machine, such that said drive means will supply insufficient torque to said at least one of said flattening rollers to cause flattened wire to be fed to said winding machine without said winding machine applying a force to the conductor wire to draw it through said wire flattening mill.

10. A method of winding at least one coil of electrical conductor wire from round conductor wire comprising the steps of:

a. passing the round conductor wire through a wire flattening mill and flattening only selected portions of the round conductor wire therein;

b. drawing the conductor wire directly from the wire flattening mill to an electrical coil winding machine wherein it is wound into the at least one electrical coil with at least a portion of a turn of round conductor wire formed in at least one electrical coil of flattened conductor wire.

11. A method of winding a plurality of coils of flattened electrical conductor wire from round conductor wire, comprising the steps of:

a. simultaneously passing a plurality of strands of round electrical conductor wire between a pair of spaced apart flattening rollers for simultaneously flattening each of the plurality of strands of conductor wire;

b. simultaneously winding the plurality of strands of conductor wire passing through the flattening rollers about the arbor of a coil winding machine for simultaneously forming a plurality of electrical coils on the coil winding machine. 

1. Apparatus for winding at least one coil of flattened electrical conductor wire from round conductor wire, comprising: a. an electrical coil winding machine including an arbor on which the at least one coil is wound, said arbor being driven to wind the conductor wire thereon; b. a supply of round conductor wire, c. a wire flattening mill interposed between said supply of round conductor wire and said coil winding machine for flattening the conductor wire as it passes from said supply to said winding machine; d. said flattening mill including a pair of spaced apart flattening roller means for selectively flattening the conductor wire as it passes therebetween; means for selectively applying a force to maintain said roller means spaced apart a predetermined amount to flatten the conductor wire and for removing the force so that non-flattened conductor wire will be provided to said arbor.
 2. Apparatus as set forth in claim 1 in which one of said roller means is movable relative to the other of said roller means; spacing means is operatively positioned between said roller means for providing the predetermined space between said roller means; said means for applying force being selectively effective to maintain said movable roller means in operative engagement with said spacing means.
 3. Apparatus as set forth in claim 2 wherein said spacing means may be varied, while the force is removed, to alter the predetermined amount of space between said roller means.
 4. Apparatus for winding a plurality of coils of flattened electrical conductor wire from round conductor wire, comprising; a. an electrical coil winding machine including an arbor about which the plurality of coils are simultaneously Wound; b. a wire supply for providing a plurality of strands of round conductor wire and c. a pair of spaced apart flattening rollers positioned between said arbor and said wire supply, the plurality of strands of conductor wire passing between said rollers for simultaneously flattening all the strands of conductor wires to substantially the same degree immediately before they are wound about said arbor.
 5. Apparatus as set forth in claim 4 further including drive means for applying a torque to at least one of said flattening rollers, the amount of applied torque being insufficient to feed the strands of conductor wire; said winding machine simultaneously applying a force to the strands of conductor wire so that the strands of conductor wire will pass between said flattening rollers and be wound about said arbor.
 6. Apparatus as set forth in claim 4 in which one of said rollers is movable relative to the other of said rollers; spacing means is operatively positioned between said rollers to provide a predetermined space between said rollers; and means selectively applying a force to said movable roller for maintaining said movable roller in operative engagement with said spacing means; so that flattened strands of conductor wire are provided to said arbor when the force is applied and non-flattened strands of conductor wire are provided to said arbor at other times.
 7. Apparatus as set forth in claim 6 in which said spacing means is selectively variable to alter the predetermined space between said flattening rollers.
 8. Apparatus as set forth in claim 5 further including synchronizing means for adjusting the torque output of said drive means in accordance with the operation of said coil winding machine, such that said drive means will always supply insufficient torque to feed flattened conductor wire to said winding machine without said winding machine applying a force to the conductor wire.
 9. Apparatus for winding at least one coil of flattened electrical conductor wire from round conductor wire, comprising: a. an electrical coil winding machine including an arbor on which the at least one coil is wound, said arbor being driven to wind the conductor wire thereon; b. a supply of round conductor wire; c. a wire flattening mill interposed between said supply of round conductor wire and said coil winding machine, including a pair of spaced apart flattening rollers for flattening the conductor wire as it passes therebetween; d. drive means for applying a torque to at least one of said flattening rollers tending to feed the conductor wire between said rollers and; e. synchronizing means for adjusting the torque output of said drive means in accordance with the operation of said coil winding machine, such that said drive means will supply insufficient torque to said at least one of said flattening rollers to cause flattened wire to be fed to said winding machine without said winding machine applying a force to the conductor wire to draw it through said wire flattening mill.
 10. A method of winding at least one coil of electrical conductor wire from round conductor wire comprising the steps of: a. passing the round conductor wire through a wire flattening mill and flattening only selected portions of the round conductor wire therein; b. drawing the conductor wire directly from the wire flattening mill to an electrical coil winding machine wherein it is wound into the at least one electrical coil with at least a portion of a turn of round conductor wire formed in at least one electrical coil of flattened conductor wire.
 11. A method of winding a plurality of coils of flattened electrical conductor wire from round conductor wire, comprising the steps of: a. simultaneously passing a plurality of strands of round electrical conductor wire between a pair of spaced apart flattening rollers for simultaneously flattening each of the plurality of strands of conductor wire; b. simultaneously winding the plurality of strandS of conductor wire passing through the flattening rollers about the arbor of a coil winding machine for simultaneously forming a plurality of electrical coils on the coil winding machine. 